Presentation of Phase 3 Monday 12/11/2006 Nick DePompeo, Brian Hufe, Mike Sacra, Ben Stuchlik

Southco  Over the past 60 years, Southco has grown through innovation, strategic acquisitions and overseas investments into a global leader in Engineered Access Hardware.  DZUS quarter-turn fasteners provide quick, effortless access/fastening for military and aerospace applications.

Project Scope Definition  To accurately design and manufacture an interface between an MTS machine and required fasteners to produce an efficient and safe testing process for all required tests.

Current Process  Utilizes 3 machines Utilizes compressed air  Requires skilled, trained operator  Tensile, shear and torsional tests are performed Tensile/Shear Fastener Testing Tensile/Shear Receptacle Testing Torque Fastener Testing

Why Change?  Three required machines to run tests  Extensive Testing time  Repetitive Testing Process  Testing process may be inaccurate  Southco has an MTS machine available

Customer Wants  Decrease skill requirement of testing procedure  Decrease testing time  Maintain testing safety standards  Develop an interface with available MTS Machine  Increase repeatability and accuracy

Metrics  Number of machines  Testing time  Accuracy  Repeatability  Durability

Benchmark-Target Value Comparison 1)3 Machines1)1 Machine (MTS Machine) 2) Approximately 8-9 hours2) Less than 4 hours per lot 3) Unknown3) 10% more accurate than what is being tested 4) Unknown4) 10% more repeatable than current process 5) N/A5) Operational for a minimum of 10 years Benchmark ValuesTarget Values

Selected Concept: Single interface for all tests Reduced setup time between tests Easily allows for “nesting” feature

Key Pieces 1)Top U Piece 2)Bottom U Piece 3)Nesting 4)Rotator Pieces

Assembly Model

Nesting  Nesting allows for adaptation. New fasteners may be tested through the use of new nesting pieces.

Locking/Unlocking Fastener

Shear to Tensile Test Re-Positioning

Design Schematic

Testing Procedure 1) Attach interface to MTS machine 2) Load TestWorks and initialize test 3) Calibrate machine 4) Performed 3 trials of testing for 3- fastener lots using required testing order 5) Record data and analyze results

Testing Results  Interface works as intended.  Testing time reduced to target value.

Test Validation- Ease of Use Current System: Requires three Machines New System: Requires 1 Machine

Test Validation- Testing Time Testing Time has been reduced by approximately 4 hours Current testing time take approximately 8 hours per lot

Test Validation- Accuracy  Load Cell is much more accurate than the current compressed air system which can have leaks.  The new system is calibrated every time a new testing shift begins.

Test Validation- Repeatability  Testing showed a high degree of repeatability. Testing time had a low std. deviation

Value to Southco  Decreased testing time More lots can be tested in a given time.  Set testing procedure Detailed step-by-step procedure  Minimizes operator skill requirements  Takes up less space

Project Costs

Implementation Plan  Southco will be provided with the interface and necessary hardware/software.  Southco will be provided with a detailed operations manual, including engineering drawings.  Southco will be provided with a first- hand training session for operators.

Financial Payback Skilled operator salary: $30/hr Current Test Time: 8.5 hr Tests per day: 1 test = $ per test Skilled operator salary: $30/hr New Test Time: 4.5 hr Tests per day: 1 test = $ per test Estimated Savings = $ per test At a total cost of $ , it would take Southco approximately 20 days of testing to completely pay off the new testing system.

Questions?